rear final drive d driveline/axle rfd a - …boredmder.com/fsms/nissan/350z/2003/rfd.pdfrfd-1 rear...

RFD-1

REAR FINAL DRIVE

D DRIVELINE/AXLE

CONTENTS

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SECTION RFDA

B

RFD

Revision; 2004 April 2003 350Z

REAR FINAL DRIVE

PREPARATION ........................................................... 2Special Service Tools ............................................... 2Commercial Service Tools ........................................ 4

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................ 5

NVH Troubleshooting Chart ..................................... 5FRONT OIL SEAL ...................................................... 6

Removal and Installation .......................................... 6REMOVAL ............................................................. 6INSTALLATION ..................................................... 7

SIDE OIL SEAL .......................................................... 8Removal and Installation .......................................... 8

REMOVAL ............................................................. 8INSTALLATION ..................................................... 8

REAR FINAL DRIVE ASSEMBLY ............................ 10Removal and Installation ........................................ 10

REMOVAL ........................................................... 10INSTALLATION ....................................................11

Components ........................................................... 12R200 2–PINION .................................................. 12R200V VISCOUS ................................................ 14

Pre-Inspection ........................................................ 15TOTAL PRELOAD ............................................... 15RING GEAR TO DRIVE PINION BACKLASH .... 15RING GEAR RUNOUT ........................................ 15TOOTH CONTACT .............................................. 15

Disassembly and Assembly ................................... 16REMOVAL OF DIFFERENTIAL CASE ASSEM-BLY ...................................................................... 16REMOVAL OF DRIVE PINION ASSEMBLY ....... 17DISASSEMBLY OF DIFFERENTIAL CASE

ASSEMBLY (R200 2–PINION) ............................ 18DISASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY(R200V) ............................................ 20INSPECTION ...................................................... 21ADJUSTMENT OF DIFFERENTIAL CASE (R200 2–PINION) ........................................................... 21ADJUSTMENT OF DIFFERENTIAL CASE (R200V) ............................................................... 22SIDE BEARING PRELOAD ................................. 23PINION GEAR HEIGHT ...................................... 24TOOTH CONTACT .............................................. 27ASSEMBLY OF DIFFERENTIAL CASE ASSEM-BLY (R200 2–PINION) ......................................... 28ASSEMBLY OF DIFFERENTIAL CASE ASSEM-BLY (R200V) ........................................................ 29INSTALLATION OF DRIVE PINION ASSEMBLY ... 30INSTALLATION OF DIFFERENTIAL CASE ASSEMBLY ......................................................... 31

SERVICE DATA AND SPECIFICATIONS (SDS) ...... 34General Specifications ............................................ 34Ring Gear Runout ................................................... 34Side Gear Adjustment ............................................ 34

AVAILABLE SIDE GEAR THRUST WASHERS ... 34Drive Pinion Height Adjustment .............................. 35

AVAILABLE PINION HEIGHT ADJUSTING WASHERS .......................................................... 35

Drive Pinion Preload Adjustment ............................ 35Side Bearing Preload Adjustment ........................... 35

SIDE BEARING ADJUSTING WASHERS .......... 35Total Preload Adjustment ........................................ 35

RFD-2

PREPARATION


PREPARATION PFP:00002

Special Service Tools ADS0005U

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool name Tool number (Kent-Moore No.)

Description

DriftST30720000 (J25405)a: 77 mm (3.03 in) dia.b: 55 mm (2.17 in) dia.

Installing front oil seal

DriftKV38100200 (J26233)a: 65 mm (2.56 in) dia.b: 49 mm (1.93 in) dia.

Installing final drive side oil seal

ProtectorKV38107900 (J39352)

Installing final drive side flange

AttachmentKV38100800 (J25604-01)a: 541 mm (21.30 in)b: 200 mm (7.87 in)

Fixing unit assembly

Differential side bearing puller set ST3306S001 ( – ) 1.ST3305S001 ( – ) 2.ST33061000 (J8107–2) a: 28.5 mm (1.122 in) dia. b: 38 mm (1.50 in) dia.

Removing and installing side bearing

DriftST30613000 (J25742-3)a: 72 mm (2.83 in) dia.

b: 48 mm (1.89 in) dia.

Installing pinion front and rear bearing outer race

DriftKV38100300 (J25523)a: 54 mm (2.13 in) dia.b: 46 mm (1.81 in) dia.c: 32 mm (1.26 in) dia.

Installing side bearing

ZZA0811D

ZZA1143D

S-NT129

SDIA0267E

NT072

ZZA0810D

ZZA1046D

PREPARATION

RFD-3

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RFD


Drive pinion flange wrenchKV40104000 ( – )a : 85 mm (3.35 in) dia.

b : 65 mm (2.56 in) dia.

Removing and installing drive pinion lock nut

Sliding hammer ST36230000 (J25840-A)

Removing side flange

Axle stand KV40104100 ( – )

Removing side flange

Slideing hammer HT72400000 ( – )

Removing differential case assembly

Drive pinion rear inner race puller set ST3090S000 ( – ) 1. ST30031000 (J22912-01) Puller 2. ST30901000 ( – ) Base Equivalent tool (J26010-01) a : 90 mm (3.54 in) dia. b : 80 mm (3.15 in) dia. c : 50 mm (1.97 in) dia. d : 79 mm (3.11 in) dia. e : 45 mm (1.77 in) dia. f : 35 mm (1.38 in) dia.

Removing and installing drive pinion rear bearing inner race

DriftST30611000 (J25742–1)

Installing pinion rear bearing outer race (Use with ST30613000)

Preload gaugeST3127S000 (see J25765-A) 1. GG91030000 Torque wrench (J25765) 2. HT62940000 ( – ) Socket adapter (1/2″) 3. HT62900000 ( – ) Socket adapter (3/8″)

Measuring pinion bearing preload and total preload


Description

NT659

ZZA0803D

ZZA0804D

S-NT125

S-NT640

S-NT090

NT124

RFD-4

PREPARATION


Commercial Service Tools ADS0005V

Side bearing outer race puller ST33290001 (J34286)

Removing oil seal

Differential shim selection (J34309) Adjusting bearing preload gear height


Description

NT713

NT134

Power tool

PBIC0190E

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

RFD-5

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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003

NVH Troubleshooting Chart ADS0005W

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.

×: Applicable

Reference page

Ref

er to

RF

D-2

1, "

Con

tact

Sur

face

s"

Ref

er to

RF

D-2

7, "

TO

OT

H C

ON

TAC

T"

Ref

er to

RF

D-2

1, "

Con

tact

Sur

face

s"

Ref

er to

RF

D-1

5, "

Pre

-Ins

pect

ion"

—

Ref

er to

MA

-21,

"C

HA

SS

IS A

ND

BO

DY

MA

INT

EN

AN

CE

"

NV

H in

PR

sec

tion.

NV

H in

FA

X, R

AX

, FS

U a

nd R

SU

sec

tions

.

NV

H in

WT

sec

tion.

NV

H in

WT

sec

tion.

NV

H in

RA

X s

ectio

n.

NV

H in

BR

sec

tion.

NV

H in

PS

sec

tion.

Possible cause and SUSPECTED PARTS

Rou

gh g

ear

toot

h

Impr

oper

gea

r co

ntac

t

Toot

h su

rfac

es w

orn

Inco

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t bac

klas

h

Com

pani

on fl

ange

exc

essi

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unou

t

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oper

gea

r oi

l

PR

OP

ELL

ER

SH

AF

T

AX

LE A

ND

SU

SP

EN

SIO

N

TIR

ES

RO

AD

WH

EE

L

DR

IVE

SH

AF

T

BR

AK

ES

ST

EE

RIN

G

Symptom DIFFERENTIAL Noise × × × × × × × × × × × × ×

RFD-6

FRONT OIL SEAL


FRONT OIL SEAL PFP:38189

Removal and Installation ADS00081

REMOVAL1. Remove the propeller shaft. Refer to PR-5, "REAR PROPELLER SHAFT" .

CAUTION:Do not impact or damage propeller shaft tube.

2. Put a mark on the end of the drive pinion corresponding to the Bposition mark on the final drive companion flange.CAUTION:● For matching mark, use paint. Never damage drive pin-

ion.● The mark on the final drive companion flange indicates

the maximum vertical runout position.

3. Using the drive pinion flange wrench, Remove drive pinion nut.

4. Using the puller, remove the companion flange.

5. Using the side bearing outer race puller, remove oil seal.

SDIA0270E

Tool number : KV40104000 ( – )

SDIA1142E

SDIA1054E

Tool number : ST33290001 (J34286)

SDIA1003E

FRONT OIL SEAL

RFD-7

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INSTALLATION1. Apply multi-purpose grease to sealing lips of oil seal. Press front

oil seal into carrier with tool.

CAUTION:● When installing the oil seal, be careful not to get it

inclined.● Discard the old oil seal. Always replace with new one.

2. Align the matching mark of drive pinion with the matching markB of companion flange, then install the companion flange.

3. Apply oil or grease on the screw part of drive pinion and the seating surface of drive pinion nut. 4. Install drive pinion nut with tool.

CAUTION:The drive pinion nut is not reusable. Never reuse drive pinion nut.5. Install propeller shaft. Refer to PR-5, "REAR PROPELLER SHAFT" .

Tool number : ST30720000 (J25405)

SDIA1004E

SDIA0270E

Tool number : KV4010400 ( - )

: 147 - 323N·m (15.0 - 32.0 kg-m, 109 - 238 ft-lb)

RFD-8

SIDE OIL SEAL


SIDE OIL SEAL PFP:33142

Removal and Installation ADS0006Q

REMOVAL1. Remove side flange with the following procedure for press-fitting.a. Remove rear ABS wheel sensor. Refer to BRC-87, "WHEEL SENSORS" .b. Remove drive shaft. Refer to RAX-10, "REAR DRIVE SHAFT" and RAX-6, "WHEEL HUB" .c. Install axle stand to side flange.

d. Using a sliding hammer, pull out the side flange.

2. Remove oil seal using a flat-bladed screwdriver.

INSTALLATIONNOTE:Be sure to install the RH companion flange of the R200V, then install the LH companion flange. If LH compan-ion flange is installed first, the RH companion flange comes out sometimes from the shock of installing the RHcompanion flange.1. Apply multi-purpose grease to sealing lips of oil seal.

2. Using the drift, press-fit oil seal so that its surface comes face toface with the end surface of the case.

CAUTION:● When installing the oil seal be careful not to get it

inclined.● Discard the old oil seal. Always replace with new one.

Tool number A : KV40104100 ( – )

Tool number B : ST36230000 (J25840–A)

SDIA1005E

ModelCircular clip installation position

Right side Left side

R200 Final drive side

R200V Final drive side Side flange side

SDIA1036E

Tool number : KV38100200 (J26233)

SDIA1037E

SIDE OIL SEAL

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3. Install the side flange with the following procedure.a. Attach the protector to side oil seal.

b. After the side flange is inserted and the serrated part of sidegear has engaged the serrated part of flange, remove the pro-tector.

c. Put suitable drift on the center of side flange, then drive it untilsound changes.NOTE:When installation is completed, driving sound of the side flangeturns into a sound which seems to affect the whole final drive.

4. Confirm that the dimension of the side flange installation (Mea-surement A) in the illustration comes into the following, theninstall the drive shaft.

5. Align the installing position of the ABS wheel sensor. Refer to BRC-87, "WHEEL SENSORS" .

Tool number : KV38107900 (J39352)

SDIA0822E

Measurement A: Approx. 326 - 328 mm (12.83 - 12.91 in) SDIA0276E

RFD-10

REAR FINAL DRIVE ASSEMBLY


REAR FINAL DRIVE ASSEMBLY PFP:38300

Removal and Installation ADS0006R

REMOVAL1. Remove rear propeller shaft from the final drive. Refer to PR-7, "REMOVAL" .

CAUTION:Do not impact or damage propeller shaft tube.

2. Remove rear stabilizer bar with power tool. Refer to RSU-16, "STABILIZER BAR" .3. Remove drive shaft from final drive. Then suspend it by wire etc.

Refer to RAX-10, "REAR DRIVE SHAFT" .4. Remove breather hose from the final drive.5. Remove ABS wheel sensor. Refer to BRC-87, "WHEEL SEN-

SORS" .6. Place a transmission jack on the final drive.

CAUTION:Do not place a transmission jack on the rear cover (alumi-num case).

7. Remove the mounting bolts and nuts connecting to the suspen-sion member, and remove the rear final drive.

SDIA1041E

SDIA1094E


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INSTALLATIONInstall in the reverse order of removal.CAUTION:After installation, check the final drive oil level. Refer to MA-24, "Checking Differential Gear Oil" .

RFD-12



Components ADS0006S

R200 2–PINION

SDIA1023E


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1. Drive pinion nut 2. Companion flange 3. Front oil seal

4. Pinion front bearing 5. Pinion bearing adjusting spacer (Collapsible spacer)

6. Pinion rear bearing

7. Pinion height adjusting washer 8. Drive pinion 9. Side oil seal

10. Ring gear 11. Pinion mate shaft 12. Look pin

13. Pinion mate gear 14. Pinion mate thrust washer 15. Side gear

16. Side gear thrust washer 17. Differential case 18. Side bearing

19. Side bearing adjusting washer 20. Bearing cap 21. Rear cover

22. Filler plug 23. Drain plug 24. Gear carrier

25. Circular clip 26. Gasket

RFD-14



R200V VISCOUS

SDIA1022E


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Pre-Inspection ADS0006T

Before disassembling final drive, perform the following inspection.

TOTAL PRELOAD1. Turn drive pinion in both directions several times to set bearing

rollers.2. Check total preload with Tool.

RING GEAR TO DRIVE PINION BACKLASHCheck ring gear to drive pinion backlash with a dial indicator at sev-eral points.

RING GEAR RUNOUTCheck runout of ring gear with a dial indicator.

TOOTH CONTACTCheck tooth contact. Refer to RFD-27, "TOOTH CONTACT" .

1. Drive pinion nut 2. Companion flange 3. Front oil seal

4. Pinion front bearing 5. Pinion bearing adjusting spacer (Collapsible spacer)

6. Pinion rear bearing

7. Pinion height adjusting washer 8. Drive pinion 9. Side oil seal

10. Ring gear 11. Pinion mate shaft 12. Pinion mate gear

13. Pinion mate thrust washer 14. Side gear thrust washer 15. Side gear

16. Viscous coupling 17. Side gear thrust washer 18. Differential case B

19. Differential case A 20. Side bearing 21. Side bearing adjusting washer

22. Bearing cap 23. Rear cover 24. Filler plug

25. Drain plug 26. Gear carrier 27. Circular clip

28. Gasket

Tool number: ST3127S000 (see J25765-A)

Total preload: 2.84 - 3.75 N·m (0.29 - 0.38 kg-m, 26 - 33 in-lb)

SPD884

Ring gear backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)

SPD513

Runout limit : 0.05 mm (0.0020 in) less

SPD886

RFD-16



Disassembly and Assembly ADS0006U

REMOVAL OF DIFFERENTIAL CASE ASSEMBLY1. Using two 45 mm (1.77 in) spacers, mount carrier on Tool.

2. For proper reinstallation, paint match marks on one side of thebearing cap.Bearing caps are line-board during manufacture. Replace themin their proper positions.

3. Remove bearing caps.

4. Lift differential case assembly out with Tool.

Tool number : KV38100800 (J25604–01)

SPD888

SPD889

S-PD343

Tool number : HT72400000 (–)

S-PD344


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● Keep the side bearing outer races together with inner races.Do not mix them up.Also, keep adjusting washers together with bearings.

REMOVAL OF DRIVE PINION ASSEMBLY1. Put match marks on companion flange and drive pinion with

paint.2. Loosen drive pinion nut with tool.

3. Using the puller remove companion flange.

4. Take out drive pinion (together with rear bearing inner race,bearing adjusting spacer).

5. Remove front oil seal. Refer to RFD-6, "FRONT OIL SEAL"6. Remove pinion front bearing inner race.7. Remove side oil seal. Refer to RFD-8, "SIDE OIL SEAL"

SPD919

Tool number : KV40104000 (–)

SDIA1144E

SDIA1132E

SPD892

RFD-18



8. Remove pinion bearing outer races with a brass drift.

9. Remove pinion rear bearing inner race and drive pinion heightadjusting washer with Tool.

DISASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY (R200 2–PINION)1. Remove side bearing inner races.

To prevent damage to bearing, engage puller jaws in groove.

SDIA0817E

Tool number: : ST30031000 (J22912-01)

S-PD179

Tool number : A ST3305S001 (–): B ST33061000 (J8107-2)

SPD920


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● Be careful not to confuse left- and right-hand parts.

2. Loosen ring gear bolts in a criss-cross fashion.3. Tap ring gear off the differential case with a soft hammer.

● Tap evenly all around to keep ring gear from binding.

4. Drive out pinion mate shaft lock pin with punch from ring gearside.

SPD022

SPD024

SPD025

RFD-20



DISASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY(R200V)1. Remove side bearing inner race.

To prevent damage to bearing, engage puller jaws in groove.

● Be careful not to confuse left- and right-hand parts.

2. Loosen ring gear bolts in a criss-cross fashion.3. Tap ring gear off the differential case with a soft hammer.

● Tap evenly all around to keep ring gear from binding.

Tool number : A ST3305S001 (–): B ST33061000 (J8107-2)

SDIA0818E

SPD022

SPD024


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4. Put match marks with paint5. Loosen screws on differential cases A and B.6. Separate differential cases A and B.

INSPECTIONContact Surfaces1. Clean the disassembled parts in suitable solvent and blow dry with compressed air.2. If following surfaces are found to be burred or scratched, smooth with oil stone.

● Differential case● Side gear● Pinion mate gear● Pinion mate shaft

Bearing1. Thoroughly clean bearing.2. Check bearings for wear, scratches, pitting or flaking.

Check tapered roller bearing for smooth rotation. If damaged,replace outer race and inner race as a set.

ADJUSTMENT OF DIFFERENTIAL CASE (R200 2–PINION)Thrust Washer Selection1. Install side gears, pinion mate gears, thrust washers into differ-

ential case.

SPD862

SPD715

SPD552

RFD-22



2. Fit pinion mate shaft to differential case so that it meets lock pinholes.

3. Adjust clearance between rear face of side gear and thrust washer by selecting side gear thrust washer.Refer to RFD-34, "AVAILABLE SIDE GEAR THRUST WASHERS" .Use two feeler gauges to prevent leaning of side gear as shown,figure.

ADJUSTMENT OF DIFFERENTIAL CASE (R200V)Side gear Thrust Washer SelectionWhenever side gears or pinion mate gears are replaced, select suit-able thrust washers as follows:1. Clean side gears and pinion mate gears using white gasoline.2. Before assembling gears, apply hypoid gear oil to frictional sur-

faces. 3. Install the previously removed thrust washer on right side gear.

On left side gear, install a suitable thrust washer.Temporarily tighten differential cases using two screws.

4. Position differential assembly so that right side gear is on theupper side. Place feeler gauge of 0.03 mm (0.0012 in) thicknessbetween right side gear and thrust washer as shown.

● Do not place feeler gauge at groove side of differential case.5. Also place a 0.03 mm (0.0012 in) additional feeler gauge between right side gear and thrust washer so

that it is positioned diagonal to (180° apart from) the feeler gauge described previously.6. Rotate right side gear with a suitable tool attached to splines. If hard to rotate, replace thrust washer on

left side gear with a thinner one.7. Replace both 0.03 mm (0.0012 in) feeler gauges with 0.15 mm (0.0059 in) gauges. At this point, make

sure right side gear does not rotate. If it rotates, replace thrust washer on left side gear with a thicker oneto prevent rotation.

8. As explained in above example, select suitable thrust washers to ensure that:a. Both side gears rotate. [0.03 mm (0.0012 in) feeler gauges are used in this case.]b. Side gear is held stationary. [0.15 mm (0.0059 in) feeler gauges are used in this case.]

For quiet and reliable final drive operation, the following five adjustments must be made correctly.1. Side bearing preload2. Pinion gear height3. Pinion bearing preload4. Ring gear to pinion backlash.

SPD553

Clearance between side gear thrust washer and differ-ential case

: 0.20 mm (0.0079 in) less

SPD828

SDIA1146E


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5. Ring and pinion gear tooth contact pattern

SIDE BEARING PRELOAD

A selection of carrier side bearing adjusting washers is required for successful completion of this procedure.1. Make sure all parts are clean. Also, make sure the bearings are

well lubricated with light oil or DEXRONTM type automatic trans-mission fluid.

2. Place the differential carrier, with side bearings and bearingraces installed, into the final drive housing.

3. Insert left and right side bearing adjusting washer in placebetween side bearings and carrier.

4. Install the side bearing caps in their correct locations and torquethe bearing cap retaining bolts.

5. Turn the carrier several times to seat the bearings.

6. Measure the turning torque of the carrier at the ring gear retain-ing bolts with a spring gauge, J-8129.

SPD527

SPD924

: 88 - 98 N·m (9.0 - 9.9 kg-m, 65 - 72 ft-lb)

SPD526

Specification: 34.2 - 39.2 N (3.5 - 4 kg, 7.7 - 8.8 lb)of pulling force at the ring gear bolt

SPD194A

RFD-24



7. If the turning torque is not within the specifications, correct thetorque as follows:● If the turning torque is less than the specified range, install

washers of greater thickness.● If the turning torque is greater than the specification, install

thinner washers.● See the SDS section for washer dimensions and part num-

bers. 8. Record the total amount of washer thickness required for the

correct carrier side bearing preload.

9. Remove the carrier from the final drive housing. Save theselected washers for later use during the assembly of the finaldrive unit.

PINION GEAR HEIGHT1. Make sure all parts are clean and that the bearings are well

lubricated.2. Assemble the pinion bearings into the differential shim selection

Tool, J34309.

● Pinion front bearing; make sure the J34309-3 pinion front bear-ing seat is secured tightly against the J34309-2 gauge anvil.Then turn the pinion front bearing pilot, J34309-5, to secure thebearing in its proper position.

● Rear pinion bearing; the pinion rear bearing pilot, J34309-8, isused to center the pinion rear bearing only. The pinion rear bear-ing locking seat, J34309-4, is used to lock the bearing to theassembly.

● Installation of J34309-9 and J34309-16; place a suitable 2.5 mm(0.098 in) thick plain washer between J34309-9 and J34309-16.Both surfaces of J34309-9 and J34309-16 must be parallel witha clearance of 2.5 mm (0.098 in).

SPD772

Tool number : HT72400000 (–)

S-PD344

SPD769

SPD197A


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3. Install the pinion rear bearing inner race into the final drive hous-ing. Then place the pinion preload shim selector Tool, J34309-1,gauge screw assembly.

4. Assemble the front pinion bearing inner race and the J34309-2gauge anvil. Assemble them together with the J34309-1 gaugescrew in the final drive housing. Make sure that the pinion heightgauge plate, J34309-16, will turn a full 360 degrees. Tighten thetwo sections together by hand.

5. Turn the assembly several times to seat the bearings.

6. Measure the turning torque at the end of the J34309-2 gaugeanvil using torque wrench J-25765A.

7. Place the J34309-11 “R200A” pinion height adapter onto thegauge plate and tighten it by hand.CAUTION:Make sure all machined surfaces are clean.

SPD893

SPD199A

SPD770

Turning torque specification: 1.0 - 1.3 N·m(0.11 - 0.13 kg-m, 9 - 11 in-lb)

SPD234A

SPD208A

RFD-26



Pinion Height Adjusting Washer Selection1. Now, position the side bearing discs, J25269-4, and arbor firmly

into the side bearing bores. Install the bearing caps and tightenthe cap bolts to proper torque.

2. Select the correct standard pinion height adjusting washer thick-ness. Select by using a standard gauge of 3 mm (0.12 in) andyour J34309-101 feeler gauge. Measure the distance betweenthe J34309-11 pinion height adapter including the standardgauge and the arbor.

3. Write down your exact measurement (the value of feeler gauge).

4. Correct the pinion height washer size by referring to the “pinionhead number”.

There are two numbers painted on the drive pinion gear. The first one refers to the drive pinion and ring gearas a matched set. This number should be the same as the number on the ring gear. The second number is the“pinion head height number”. It refers to the ideal pinion height from standard for quietest operation. Use thefollowing chart to determine the correct pinion height washer.

SPD211A

SPD204A

SPD775

SPD542


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5. Select the correct pinion height washer as follows. Refer to RFD-35, "AVAILABLE PINION HEIGHTADJUSTING WASHERS" .

6. Remove the J34309 pinion differential shim selection Tool fromthe final drive housing. Then disassemble to retrieve the pinionbearings.

TOOTH CONTACTChecking gear tooth contact pattern is necessary to verify correct relationship between ring gear and drive pin-ion.Hypoid gears which are not positioned in proper arrangement may be noisy and/or have a short life. Checkgear tooth contact pattern to obtain the best contact for low noise and long life.

1. Thoroughly clean ring gear and drive pinion teeth.2. Lightly apply a mixture of powdered ferric oxide and oil or the

equivalent. Apply it to 3 or 4 teeth of ring gear drive side.

3. Hold companion flange steady by hand and rotate the ring gearin both directions.

Pinion head height numberAdd or remove from the standardpinion height washer thickness measurement

- 6- 5- 4- 3- 2- 10

+1+2+3+4+5 +6

Add 0.06 mm (0.0024 in)Add 0.05 mm (0.0020 in)Add 0.04 mm (0.0016 in)Add 0.03 mm (0.0012 in)Add 0.02 mm (0.0008 in)Add 0.01 mm (0.0004 in)Use the selected washer thicknessSubtract 0.01 mm (0.0004 in)Subtract 0.02 mm (0.0008 in)Subtract 0.03 mm (0.0012 in)Subtract 0.04 mm (0.0016 in)Subtract 0.05 mm (0.0020 in)Subtract 0.06 mm (0.0024 in)

SPD205A

SPD357

SDIA0813E

RFD-28



ASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY (R200 2–PINION)1. Install pinion mate shaft lock pin with a punch.

Make sure lock pin is flush with case.

2. Place differential case on ring gear.3. Apply genuine medium strength locking sealant or equivalent.

Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTSAND SEALANTS" to ring gear bolts, and install them.

● Tighten bolts in a criss-cross fashion.● After tightening the bolt to the specified torque, turn the bolt 31

to 36 more degrees.

4. Press-fit side bearing inner races on differential case with Tool.

SDIA0821E

SPD030

SPD554

Tool number : A KV38100300 (J25523): B ST33061000 (J8107-2)

SPD353


RFD-29

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ASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY (R200V)1. Install differential cases A and B.

2. Place differential case on ring gear.3. Apply genuine medium strength locking sealant or equivalent.

Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTSAND SEALANTS" to ring gear bolts, and install them.

● Tighten bolts in a criss-cross fashion.● After tightening the bolt to the specified torque, turn the bolt 31

to 36 more degrees.

4. Press-fit side bearing inner races on differential case with Tool.

: 3.8 - 5.8 N·m(0.39 - 0.59 kg-m, 34 - 51 in-lb)

SPD862

SPD554

Tool number : A KV38100300 (J25523): B ST33061000 (J8107-2)

SPD353

RFD-30



INSTALLATION OF DRIVE PINION ASSEMBLY1. Press-fit pinion front and rear bearing outer races with Tools.

2. Select pinion height adjusting washer. Refer to RFD-26, "Pinion Height Adjusting Washer Selection" .

3. Install selected pinion height adjusting washer in drive pinion.Using press and Tool, press-fit pinion rear bearing inner raceinto it.

4. Set drive pinion assembly (as shown in figure) in differential car-rier and install drive pinion, with press and suitable tool.Stop when drive pinion touches bearing.Apply multi-purpose grease to pinion rear bearing inner raceand pinion front bearing inner race.

Tool number : A Suitable tool: B ST30611000 (J25742-1): C ST30613000 (J25742-3)

SPD992

Tool number : ST30901000 (–)

SPD377

SDIA0826E


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5. Install front oil seal with Tool. Refer toRFD-6, "Removal and Installation" .

6. Install companion flange, and tighten pinion nut to minimum.Ascertain that threaded portion of drive pinion and drive pinionnut are free from oil or grease.

CAUTION:The drive pinion nut is not reusable. Never reuse drive pinionnut.

7. Tighten the drive pinion nut by very small degrees until the spec-ified preload in achieved, when checking the preload, turn drivepinion in both directions several times.

● If pinion bearing preload is too small, tighten the drive pinion nut more.● If pinion bearing preload is too great, replace pinion bearing adjusting spacer.

INSTALLATION OF DIFFERENTIAL CASE ASSEMBLY1. Select side bearing adjusting washer. Refer to RFD-23, "SIDE

BEARING PRELOAD" .2. Install differential case assembly with side bearing outer races

into gear carrier.

SPD896

Tool number : KV40104000 (–)

SDIA1145E

Tool number: ST3127S000 (See J25765-A)

Pinion bearing preload : 2.65 - 3.23 N·m (0.27 - 0.32 kg-m, 24 - 28 in-lb)

SPD884

SPD919

RFD-32



3. Insert left and right side bearing adjusting washers in placebetween side bearings and carrier.

4. Align mark on bearing cap with that on gear carrier and installbearing cap on gear carrier.

5. Install side oil seal. Refer to RFD-8, "Removal and Installation" .

6. Measure ring gear-to-drive pinion backlash with a dial indicatorat several point.

● It backlash is too small, adjustment of washer thickness is required. Decrease thickness of left shim andincrease thickness of right by the same amount.If backlash is too great, reverse the above procedure.

● Never change the total amount of washers as it will change the bearing preload.

7. Check total preload with Tool.

When checking preload, turn drive pinion in both directions several times to seat bearing rollers correctly.

SPD924

: 88 - 98 N·m (9.0 - 9.9 kg-m, 65 - 72 fl-lb)

SPD889

Ring gear backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in) less

SPD513

Tool number : ST3127S000 (See J25765-A)

SPD884

Total preload : 2.84 - 3.75 N·m (0.29 - 0.38 kg-m, 26 - 33 in-lb)


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● If preload is too great, remove the same amount of washer to each side.● If preload is too small, add the same amount of washer to each side.

Never add or remove a different number of washers for each side. Difference in number of washers willchange ring gear to drive pinion backlash.

8. Recheck ring gear to drive pinion backlash. Increase or decrease in thickness of shims will cause changeto ring gear to pinion backlash.

● Check whether the backlash varies excessively in different places. Foreign matter may be caughtbetween the ring gear and the differential case causing the trouble.

● The backlash can vary greatly even when the ring gear runout is within a specified range. In that case,replace the hypoid gear set or differential case.

9. Check runout of ring gear with a dial indicator.

10. Check tooth contact.Refer to RFD-27, "TOOTH CONTACT" .

11. Install rear cover. Apply sealant to rear cover side and installgear carrier.

Runout limit : 0.05 mm (0.0020 in) less

SPD524

SDIA0970E

RFD-34

SERVICE DATA AND SPECIFICATIONS (SDS)


SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

General Specifications ADS0008B

Ring Gear Runout ADS0008C

Unit: mm (in)

Side Gear Adjustment ADS0008H

Unit: mm (in)

AVAILABLE SIDE GEAR THRUST WASHERS Unit: mm (in)

Applied modelVQ35DE engine

M / T A / T

Final drive model R200 (2 − pinion) R200V (LSD)

Gear ratio 3.538 3.357

Number of teeth (Ring gear / drive pinion) 46 / 13 47 / 14

Oil capacity (Approx.) 1.4 liter (3 US pt, 2 - 1/2 Imp pt)

Type R200, R200V

Ring gear runout limit 0.05 (0.0020) less

Type R200 R200V

Clearance limit between side gear and differential case mm (in) 0.20 (0.0079) less 0.15 (0.0059) less

Type R200 R200V

Thrust washer

Thickness Part number Thickness Part number

0.75 (0.0295) 38424 0C000 0.80 (0.0315) 38424 40F60

0.78 (0.0307) 38424 0C001 0.83 (0.0327) 38424 40F61

0.81 (0.0319) 38424 0C002 0.86 (0.0339) 38424 40F62

0.84 (0.0331) 38424 0C003 0.89 (0.0350) 38424 40F63

0.87 (0.0343) 38424 0C004 0.92 (0.0362) 38424 40F64

0.90 (0.0350) 38424 0C005 0.95 (0.0374) 38424 40F65

0.93 (0.0366) 38424 0C006 0.98 (0.0386) 38424 40F66

1.01 (0.0398) 38424 40F67

1.04 (0.0409) 38424 40F68

1.07 (0.0421) 38424 40F69

1.10 (0.0433) 38424 40F70

1.13 (0.0445) 38424 40F71

1.16 (0.0457) 38424 40F72

1.19 (0.0469) 38424 40F73

1.22 (0.0480) 38424 40F74

1.25 (0.0492) 38424 40F75

1.28 (0.0504) 38424 40F76

1.31 (0.0516) 38424 40F77

1.34 (0.0528) 38424 40F78

1.37 (0.0539) 38424 40F79

1.40 (0.0551) 38424 40F80

1.43 (0.0563) 38424 40F81

1.46 (0.0575) 38424 40F82

1.49 (0.0587) 38424 40F83


RFD-35

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Drive Pinion Height Adjustment ADS0008J

AVAILABLE PINION HEIGHT ADJUSTING WASHERSUnit: mm (in)

Drive Pinion Preload Adjustment ADS0008K

Side Bearing Preload Adjustment ADS0008L

SIDE BEARING ADJUSTING WASHERSUnit: mm (in)

Total Preload Adjustment ADS0008M

Type R200, R200V

Adjusting washer


3.05 (0.1201) 38154 0C000 3.35 (0.1319) 38154 0C010

3.08 (0.1213) 38154 0C001 3.38 (0.1331) 38154 0C011

3.11 (0.1224) 38154 0C002 3.41 (0.1343) 38154 0C012

3.14 (0.1236) 38154 0C003 3.44 (0.1354) 38154 0C013

3.17 (0.1248) 38154 0C004 3.47 (0.1366) 38154 0C014

3.20 (0.1260) 38154 0C005 3.50(0.1378) 38154 0C015

3.23 (0.1272) 38154 0C006

3.26 (0.1283) 38154 0C007

3.29 (0.1295) 38154 0C008

3.32 (0.1307) 38154 0C009

Type R200, R200V

Drive pinion preload 2.65 − 3.23 N·m (0.27 − 0.32 kg−m, 24 − 28 in lb)

Type R200, R200V

Side bearing preload <Reference value> 0.20 − 0.52 N·m (0.02 − 0.05 kg−m, 2 − 4 in lb)

Torque by spring gauge 34.2 − 39.2 N (3.5 − 4 kg, 7.7 − 8.8 lb)

Type R200, R200V

Adjusting washer


2.00 (0.0787) 38453 N3100 2.35 (0.0925) 38453 N3107

2.05 (0.0807) 38453 N3101 2.40 (0.0945) 38453 N3108

2.10 (0.0827) 38453 N3102 2.45 (0.0965) 38453 N3109

2.15 (0.0846) 38453 N3103 2.50 (0.0984) 38453 N3110

2.20 (0.0866) 38453 N3104 2.55 (0.1004) 38453 N3111

2.25 (0.0886) 38453 N3105 2.60 (0.1024) 38453 N3112

2.30 (0.0906) 38453 N3106 2.65 (0.1043) 38453 N3113

Type R200, R200V

Total preload with oil seal 2.84 − 3.75 N·m (0.29 − 0.38 kg−m, 26 − 33 in lb)

Ring gear to drive pinion backlash 0.10 − 0.15 mm (0.0039 − 0.0059 in)

RFD-36



rear final drive d driveline/axle rfd a - …boredmder.com/fsms/nissan/350z/2003/rfd.pdfrfd-1 rear...

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